Open cell spray fire-retardant foam

Patent metadata

Field	Value
Publication number	US-10118985-B2
Application number	US-201514661737-A
Country	US
Kind code	B2
Filing date	Mar 18, 2015
Priority date	Mar 18, 2015
Publication date	Nov 6, 2018
Grant date	Nov 6, 2018

Abstract

Embodiments of the present technology may include an open cell spray polyurethane foam. The foam may include a polymer. The polymer may formed by the polymerization of a reaction product of (1) a saccharide with an epoxide and (2) an isocyanate. The reaction product may have greater than 25 weight percent and less than 99 weight percent of the saccharide. The foam may exhibit a fire retardancy sufficient to pass flame tests in accordance with Appendix X and/or ASTM E-4.

First claim

What is claimed is:

1. An open cell spray polyurethane foam, the foam comprising a polyurethane formed by a polymerization of:
a polyether polyol consisting of a product formed by a reaction of reactants consisting of a saccharide with an epoxide, wherein greater than 25 wt. % and less than 99 wt. % of the polyether polyol is from the saccharide; and
an isocyanate, wherein:
the saccharide is sucrose, and
the foam excludes greater than 10 wt. % free sucrose.

2. The foam of claim 1 , wherein the foam exhibits a fire retardancy sufficient to pass flame tests in accordance with at least one of Appendix X and ASTM E-84.

3. The foam of claim 1 , wherein the epoxide comprises ethylene oxide, propylene oxide, or a mixture thereof.

4. The foam of claim 1 , wherein the foam further comprises a flame retardant that does not include a product formed from the saccharide.

5. The foam of claim 1 , wherein greater than 30 wt. % and less than 89 wt. % of the polyether polyol is from the saccharide.

6. The foam of claim 1 , wherein greater than 40 wt. % and less than 89 wt. % of the polyether polyol is from the saccharide.

7. The foam of claim 1 , wherein greater than 50 wt. % and less than 89 wt. % of the polyether polyol is from the saccharide.

8. The foam of claim 1 , wherein the polyether polyol comprises a molecular formula of:

wherein:
a, b, c, and d are non-negative integers, and
a+b+c+d is from 1 to 23.

9. The foam of claim 1 , wherein two hydroxyl groups of the sucrose react with the epoxide.

10. The foam of claim 1 , wherein the epoxide comprises ethylene oxide, propylene oxide, or a mixture thereof.

11. The foam of claim 1 , wherein the foam has a density of between about 0.3 pcf and 0.7 pcf.

12. The foam of claim 1 , wherein the foam excludes free sucrose.

13. The foam of claim 1 , wherein the epoxide comprises a mixture with more ethylene oxide than propylene oxide.

14. The foam of claim 1 , wherein the polyether polyol comprises a hydroxyl group bonded to a primary carbon, and the hydroxyl group comprises an oxygen atom from the epoxide.

15. The foam of claim 1 , wherein the epoxide comprises a mixture of ethylene oxide and propylene oxide.

16. The foam of claim 15 , wherein the polyether polyol comprises two hydroxyl groups of the sucrose reacted with the epoxide.

17. The foam of claim 1 , wherein the polyurethane is formed by a polymerization consisting of the polyether polyol and the isocyanate.

18. A formulation for forming an open cell spray foam, the formulation comprising by weight:
16-61% a polyether polyol consisting of a product formed by a reaction of reactants consisting of a saccharide with an epoxide, wherein greater than 25 wt. % and less than 99 wt. % of the polyether polyol is from the saccharide, wherein the formulation excludes greater than 10 wt. % free sucrose.

19. The formulation of claim 18 , further comprising:
0-30% polyol;
9-36% TCPP;
2-16% amine catalyst;
3-22% emulsifier;
0.3-4% surfactant; and
9-36% water.

20. The formulation of claim 18 , wherein the saccharide is sucrose.

Assignees

• Johns Manville

Inventors

• Snider Scott
• Wang Lance
• Asrar Jawed

Classifications

• C08J2205/05

  Open cells, i.e. more than 50% of the pores are open · CPC title

• C08G18/7664

  containing alkylene polyphenyl groups · CPC title

• C08G18/4837 Primary

  and other oxyalkylene units · CPC title

• C08J9/04

  using blowing gases generated by a previously added blowing agent · CPC title

• C08J2207/04

  Aerosol, e.g. polyurethane foam spray · CPC title